US8056432B2 - Active control stick assembly - Google Patents

Abstract

An active control stick assembly is provided. In one embodiment, the active control stick assembly includes a housing assembly, and a control stick support body mounted within the housing assembly for rotation about two substantially orthogonal and co-planar rotational axes. A control stick is fixedly coupled to the control stick support body and rotatable along therewith from a null position to a plurality of control positions. A first spring element is coupled between the housing assembly and the control stick support body and passively biases the control stick toward the null position.

Description

TECHNICAL FIELD

The present invention relates generally to human-machine control interfaces and, more particularly, to an active control stick assembly suitable for deployment on an aircraft.

BACKGROUND

Modern aircraft are commonly equipped with one or more active control stick assemblies that permit a pilot to control various aspects of aircraft flight. An inceptor-type control stick assembly, for example, may be deployed on a fixed wing aircraft and utilized to control the aircraft's pitch and yaw. The inceptor-type control stick assembly includes an elongated control stick that extends upward from a housing assembly mounted in the aircraft cockpit, typically in either a center stick or side stick disposition. The lower end of the control stick is affixed to a gimbal or double cardon assembly disposed within the housing assembly. The gimbal or double cardon assembly permits the control stick to be rotated relative to the housing assembly about first and second rotational axes (i.e., the pitch and roll axes). One or more position sensors are further disposed within the housing assembly and monitor control stick movement. During flight, the position sensors generate positions indicative of the control stick movement, which are subsequently utilized to alter the position of the aircraft's movable flight surfaces and thereby adjust the aircraft's pitch and yaw.

There has been a recent migration in the aircraft industry toward “active” control stick assemblies capable of providing tactile cueing; i.e., haptic force feedback imparted to the control stick indicative of the aircraft's current flight parameters. In general, such active control stick assemblies include at least one artificial force feel (AFF) motor (e.g., a brushless direct current motor) that is selectively energized by a controller. The AFF motor is mechanically coupled to the control stick by a speed reducer, which is conventionally either a gearbox or a harmonic drive. When energized by the controller, the AFF motor drives through the speed reducer to exert a controlled torque on the control stick about one or more of the rotational axis. In this manner, the active control stick assembly generates haptic force feedback, which may be varied by commands from the Flight Control Computers, commensurate with current aircraft attitude and flight conditions.

Although providing the pilot with feedback in a rapid and intuitive manner, conventional inceptor-type active control stick assemblies are limited in certain respects. The gimbal or double cardon architectures employed by such active control stick assemblies commonly employ a relatively large number of components, such as various brackets, bearings, and the like. As a result, such active control stick assemblies are often undesirably complex and costly to produce. In addition, such active control stick assemblies tend to be relatively bulky and may be difficult to integrate into the limited space available within an aircraft's cockpit.

Accordingly, it is desirable to provide an active control stick assembly suitable for deployment onboard an aircraft that eliminates the complex gimbal assemblies and double carbon arrangements employed by conventional control stick assemblies. Preferably, such an active control stick assembly would be less costly to produce, would have a reduced part count, and would have a streamlined envelope as compared to conventional control stick assemblies. Other desirable features and characteristics of the present invention will become apparent from the subsequent Detailed Description and the appended claims, taken in conjunction with the accompanying drawings and this Background.

BRIEF SUMMARY

An active control stick assembly is provided. In one embodiment, the active control stick assembly includes a housing assembly, and a control stick support body mounted within the housing assembly for rotation about two substantially orthogonal and co-planar rotational axes. A control stick is fixedly coupled to the control stick support body and rotatable along therewith from a null position to a plurality of control positions. A first spring element is coupled between the housing assembly and the control stick support body and passively biases the control stick toward the null position.

BRIEF DESCRIPTION OF THE DRAWINGS

At least one example of the present invention will hereinafter be described in conjunction with the following figures, wherein like numerals denote like elements, and:

FIG. 1 is top plan view of an active control stick in accordance with a first exemplary embodiment;

FIGS. 2 and 3 are top and bottom isometric views, respectively, of the active control stick shown inFIG. 1 having the cover removed for clarity;

FIGS. 4 and 5 are plan cross-sectional views of the active control stick shown inFIGS. 1 and 2 taken along lines4-4 and5-5, respectively, as labeled inFIG. 1; and

FIG. 6 is a plan cross-sectional view of an active control stick in accordance with a second exemplary embodiment.

DETAILED DESCRIPTION

The following Detailed Description is merely exemplary in nature and is not intended to limit the invention or the application and uses of the invention. Furthermore, there is no intention to be bound by any theory presented in the preceding Background or the following Detailed Description.

FIG. 1 is a top plan view of an activecontrol stick assembly20 in accordance with a first exemplary embodiment; andFIGS. 2 and 3 are upper and lower isometric views of activecontrol stick assembly20, respectively. In the exemplary embodiment shown inFIGS. 1-3 and described below, activecontrol stick assembly20 assumes the form of an inceptor-type control stick assembly commonly deployed within the cockpit of a fixed wing aircraft and utilized to control aircraft pitch and yaw. This example notwithstanding, alternative embodiments of the active control stick assembly may be deployed on other types of vehicles and machinery, such as excavation equipment, cranes, and the like.

Activecontrol stick assembly20 includes acontrol stick24, which may assume the form of an elongated cylindrical body.Active control stick20 is fixedly coupled (e.g., bolted) to an upper portion of a control stick support body26 (shown in phantom inFIG. 1), which is rotatably mounted within ahousing assembly28.Housing assembly28 may include any number of structural components suitable for supporting controlstick support body26 while permitting the rotational movement thereof. In the exemplary embodiment shown inFIGS. 1-3,housing assembly28 includes a base32 (shown inFIGS. 2 and 3), a cradle34 (shown inFIGS. 2 and 3), and a cover30 (shown inFIG. 1).Cradle34 is fixedly coupled tobase32 and may be integrally formed therewith. Similarly,cover30 is fixedly coupled tobase32 utilizing, for example, a plurality of bolts (not shown) or other such fasteners. As shown most clearly inFIG. 1, acentral aperture36 is provided throughcover30.Control stick24, and perhaps an upper portion of controlstick support body26, extends throughaperture36 so as to be manually accessible from the exterior ofhousing assembly28.

Controlstick support body26 is mounted withinhousing assembly28 for rotation about first and secondrotational axes38 and39 (labeled inFIG. 2), which are preferably substantially orthogonal and co-planar. As noted above,control stick24 is affixed to an upper portion of controlstick support body26.Control stick24 may thus also rotate along with controlstick support body26 aboutrotational axes38 and39.Control stick24 and controlstick support body26 normally reside in a null position (illustrated inFIGS. 1-3). During operation, a pilot selectively rotatescontrol stick24, and therefore supportbody26, aboutrotational axes38 and39 from the null position to a plurality of control positions to control various aspects of aircraft flight. Whencontrol stick assembly20 assumes the form of an aircraft inceptor, first and secondrotational axes38 and39 may correspond to an aircraft's pitch and roll axes, respectively. In this case,control stick assembly20 may be mounted such that controlstick support body26 rotates: (i) about firstrotational axis38 as a pilot movescontrol stick24 in a left or right direction, and (ii) about secondrotational axis39 as a pilotmoves control stick24 in a forward or aft direction.Control stick assembly20 further permitscontrol stick24 to be moved in a combined forward-left direction, a combined forward-right direction, a combined aft-left direction, or a combined aft-right direction, and back to or through the null position. In a preferred embodiment,control stick24 is mounted to controlstick support body26 such that the longitudinal axis ofcontrol stick24 is substantially perpendicular torotational axes38 and39 when in the null position; however,control stick24 may also be mounted to controlstick support body26 in a manner such that the longitudinal axis ofcontrol stick24 is either offset relative to the intersection of the two rotational axes and/or angled with respect to one or both of the rotational axes.

FIGS. 4 and 5 are plan cross-sectional views ofcontrol stick assembly20 taken along lines4-4 and5-5, respectively, as labeled inFIG. 1. InFIGS. 4 and 5, it can be seen thatcradle34 and cover30 cooperate to define a socket in which controlstick support body26 resides. Although controlstick support body26 may assume a variety of geometries, it is preferred that controlstick support body26 assumes a generally spherical shape, such as the shape of a perfect sphere, a flattened sphere, or other such sphere. In the exemplary embodiment illustrated inFIGS. 4 and 5, controlstick support body26 assumes the shape of a flattened sphere. In this case, controlstick support body26 may include generally convex or domed upper andlower portions40 and42. Whencontrol stick assembly20 is assembled, domedlower portion42 seats within a guide feature provided in, on, or throughcradle34. This guide feature may comprise, for example, a concavity or other such depression that matingly receives domedlower portion42 therein. Alternatively, and as shown inFIGS. 4 and 5, the guide feature may comprise anopening44 provided through a central portion ofcradle34. The inner edge ofcradle34 defining opening44 contacts domedlower portion42 to guide the rotational movement of controlstick support body26 and to generally prevent lateral movement ofsupport body26 withinhousing assembly28. If desired, the inner edge ofcradle34 definingcentral opening44 may have a tapered or sloped geometry to better mate with the curved outer surface of domedlower portion42.

In the illustrated exemplary embodiment, cover30 also contacts controlstick support body26 to guide the rotational movement thereof. More specifically, the inner edge ofcover30 definingaperture36 contacts domedupper portion40 of controlstick support body26 to guide the rotational movement thereof. Again, the inner edge ofcover30 definingaperture36 may have a tapered or sloped shape to better mate with the sloped outer surface of domedupper portion40. As does the inner edge ofcradle34 definingopening44, the inner edge ofcover30 definingaperture36 generally prevents lateral movement ofsupport body26 withinhousing assembly28. Furthermore, the inner edge ofcradle34 cooperates with the inner edge ofcover30 to generally prevent the vertical movement of controlstick support body26 withinhousing assembly28. In this manner,cradle34 and cover30 cooperate to restrict the movement of controlstick support body26, and therefore the movement ofcontrol stick24, to rotational movement aboutrotational axes38 and39 (FIG. 2). This example notwithstanding, it will be appreciated that alternative embodiments ofcontrol stick assembly20 may include other types of guide features suitable for restricting the movement of controlstick support body26 in this manner.

Control stick assembly20 further includes one or more spring element mechanically coupled between controlstick support body26 andhousing assembly28. The number, type, and orientation of the spring element or elements employed bycontrol stick assembly20 will inevitably vary amongst different embodiments of the present invention. In the exemplary embodiment illustrated inFIGS. 1-5, controlstick assembly20 comprises fourcoil springs46,48,50, and52, which are each disposed between a component ofhousing assembly28 and controlstick support body26. More specifically, coil springs46,48,50, and52 each include a first end portion, which is fixedly coupled to an outer step provided aroundcradle34, and a second opposing end portion, which is fixedly coupled to a peripheral portion of controlstick support body26; e.g., an end portion of eachcoil spring46,48,50, and52 may be fixedly coupled to a differentradial flange54 angularly spaced about a circumferential portion of controlstick support body26. If desired, an annular depression may be provided within eachradial flange54 to help retainsprings46,48,50, and52 in place. As may be appreciated most easily by referring toFIG. 1, springs46,48,50, and52 are preferably positioned such that each spring is substantially equidistant from the longitudinal axis ofcontrol stick24 when in the null position. Collectively, coil springs46,48,50, and52 passively bias controlstick support body26, and thus controlstick24, toward the null position shown inFIGS. 1-5.

Control stick assembly20 further includes first and second artificial force feel (AFF)actuators58 and60.AFF actuators58 and60 are each mechanically coupled between controlstick support body26 and a stationary mounting structure generally referred to herein as “the aircraft chassis.” For example, and referring especially toFIG. 4, a first end ofAFF actuator60 may be coupled to aradial flange54 of controlstick support body26 via a first hinged coupling62 (e.g., a first clevis), and the opposing end ofAFF actuator60 may be coupled to a firstchassis mounting structure66 via a second hinged coupling68 (e.g., a second clevis). Similarly, and with reference toFIG. 5, a first end ofAFF actuator58 may be coupled to aradial flange54 of controlstick support body26 via a third hinged coupling70 (e.g., a third clevis), and the opposing end ofAFF actuator58 may be coupled to a secondchassis mounting structure65 via a fourth hinged coupling72 (e.g., a fourth clevis). When coupled between controlstick support body26 and the aircraft chassis in this manner,AFF actuators58 and60 reside adjacent coil springs48 and50, respectively, and the longitudinal axes ofAFF actuators58 and60 are substantially parallel.AFF actuators58 and60 may be implemented utilizing any suitable hydraulic or pneumatic device, although it is preferred thatAFF actuators58 and60 each comprise an electric device, such as a ballscrew actuator. During operation, a controller selectively energizes (or otherwise activates) first andsecond AFF actuators58 and60 to provide haptic force feedback to controlstick24 aboutrotational axes38 and39, respectively, in accordance with commands issued from one or more Flight Control Computers deployed on the aircraft and commensurate with current aircraft attitude and flight conditions.

It should thus be appreciated that there has been provided an exemplary embodiment of an active control stick assembly that includes a plurality of coils springs angularly spaced about a peripheral portion of a control stick support body rotatably mounted within a housing assembly. It should also be appreciated that, in the above-described exemplary embodiment, first and second linear actuators are employed to impart haptic force feedback to the control stick support body and, thus, the control stick. The foregoing notwithstanding, alternative embodiments of the active control stick assembly may employ other types of actuator and different arrangements of the spring element or elements. Further illustrating this point,FIG. 6 is a simplified cross-sectional view of an activecontrol stick assembly80 in accordance with a second exemplary embodiment. In many respects,control stick assembly80 is similar to controlstick assembly20 described above in conjunction withFIGS. 1-5. For example, activecontrol stick assembly80 includes anelongated control stick82 that is fixedly coupled (e.g., bolted) to the upper portion of a controlstick support body84 rotatably disposed within a housing assembly86. As was the case previously, housing assembly86 includes acradle88 and acover90 that engage opposing portions of controlstick support body84 to generally restrict the movement ofsupport body84, and therefore the movement ofcontrol stick82, to rotational about two substantially orthogonal rotational axes. However, in contrast to control stick assembly20 (FIGS. 1-5), control stick assembly80 (FIG. 6) does not include a plurality of spring elements coupled between an outer peripheral portion of controlstick support body84 and housing assembly86. Instead, controlstick assembly80 includes a single element, acoil spring92, which is mechanically coupled between a central portion of controlstick support body84 and housing assembly86. If desired, and as indicated inFIG. 6, an annular depression may be provided within a lower portion of controlstick support body84 to help retaincoil spring92 in place. During operation ofcontrol stick assembly80,coil spring92 passively biases controlstick support body84 and control stick82 toward a null position illustrated inFIG. 6.

In addition to employing a single, centrally-coupled spring element,control stick assembly80 differs from control stick assembly20 (FIGS. 1-5) in another manner as well; i.e., controlstick assembly80 employs one or morerotary actuators94, as opposed to one or more linear actuators, to provide active force feedback to controlstick82. As shown inFIG. 6, a firstrotary actuator94 is mechanically linked to opposing end portions of controlstick support body84 via first andsecond cables96 and98. For example,cable96 may be rotatably coupled to supportbody84 utilizing afirst clevis100, andcable98 may be rotatably coupled to an opposing end ofsupport body84 utilizing asecond clevis102. During operation, a controller (not shown) causesrotary actuator94 to selectively retract and let outcables96 and98 to impart controlled torque about controlstick support body84 about a first rotational axis and thereby provide haptic force feedback to controlstick82. Although not shown inFIG. 6 for clarity, a second rotary actuator may also be mechanically linked to supportbody84 and configured to impart torque to supportbody84 about a second rotational axis, which is substantially orthogonal to and coplanar with the first rotational axis, to further provide haptic force feedback to controlstick82 in the above-described manner.

It should thus be appreciated that there has been provided multiple exemplary embodiments of an active control stick assembly suitable for deployment on an aircraft that eliminates the complex gimbal assemblies and double carbon arrangements employed by conventional control stick assemblies. It should further be appreciated that the embodiments of the active control stick assembly are generally less costly to produce, have a reduced part count, and have a more compact envelope as compared to conventional control stick assemblies. Although, in the above-described embodiments, the spring elements each assumed the form of a coil spring, this may not always be the case; in alternative embodiments, the spring elements may assume other forms suitable for passively biasing the control stick support body toward the null position. For example, in certain embodiments, one or more of the spring elements may assume the form of a resilient metal body having or more slits therethrough and commonly referred to as machined spring. Alternatively, leaf springs and torsional springs or bars may also be employed.

While at least one exemplary embodiment has been presented in the foregoing Detailed Description, it should be appreciated that a vast number of variations exist. It should also be appreciated that the exemplary embodiment or exemplary embodiments are only examples, and are not intended to limit the scope, applicability, or configuration of the invention in any way. Rather, the foregoing Detailed Description will provide those skilled in the art with a convenient road map for implementing an exemplary embodiment of the invention. It being understood that various changes may be made in the function and arrangement of elements described in an exemplary embodiment without departing from the scope of the invention as set-forth in the appended claims.

Claims (13)

1. An active control stick assembly, comprising:

a housing assembly, comprising:

a cradle having an opening therethrough;

a cover fixedly coupled to the cradle;

a control stick support body mounted within the housing assembly for rotation about two substantially orthogonal and co-planar rotational axes, the control stick support body having a domed lower portion seating on the opening in the cradle;

a control stick fixedly coupled to the control stick support body and rotatable along therewith from a null position to a plurality of control positions, the control stick extending from the control stick support body through the cover; and

a centrally-disposed spring element coupled between the housing assembly and the control stick support body and passively biasing the control stick toward the null position, the centrally-disposed spring element engaging the domed lower portion of the control stick support body exposed through the opening in the cradle.

2. An active control stick assembly according toclaim 1 wherein the first spring element comprises:

a first end portion fixedly coupled to the housing assembly; and

a second end portion substantially opposite the first end portion and fixedly coupled to a lower surface of the control stick support body.

3. An active control stick assembly according toclaim 1 wherein the upper portion of the control stick support body has a generally domed shape, and wherein the cover includes a sloped inner edge defining an opening through which the control stick extends, the sloped inner edge contacting the upper portion so as to generally prevent the lateral movement of the control stick support body and the control stick.

4. An active control stick assembly according toclaim 1 further comprising a first artificial force feel (AFF) actuator coupled to the control stick support body and configured to selectively supply a torque to the control stick support body about the first rotational axis.

5. An active control stick assembly according toclaim 4 further comprising a second AFF actuator coupled to the control stick support body and configured to selectively supply a torque to the control stick support body about the second rotational axis.

6. An active control stick assembly according toclaim 5 wherein the active control stick assembly is configured to deployed on an aircraft, and wherein the first AFF actuator and the second AFF actuator cooperate to provide active force feedback to the control stick indicative of at least one flight parameter of the aircraft.

7. An active control stick assembly according toclaim 1 wherein the control stick support body has a generally spherical shape.

8. An active control stick assembly, comprising:

a housing assembly, comprising:

a cradle; and

a cover fixedly coupled to the cradle and having a central opening therethrough;

a control stick extending through the central opening;

a generally spherical control stick support body rigidly coupled to the control stick and disposed between the cradle and the cover, the generally spherical control stick support body mounted within the housing assembly for rotation about two substantially orthogonal rotational axes so as to permit the control stick to be rotated from a null position to a plurality of control positions; and

a first spring element coupled between the housing assembly and the generally spherical control stick support body and passively biasing the control stick toward the null position;

wherein the cradle has a sloped inner circumferential edge on which the generally spherical control stick support body seats, the sloped inner circumferential edge of the cradle and the central opening provided in the cover cooperating to define a socket occupied by the spherical control stick support body.

9. An active control stick assembly according toclaim 8 wherein the control stick support body comprises:

a first radial flange, the first spring element compressed between the first radial flange and the housing assembly; and

a second radial flange angularly spaced from the first radially flange.

10. An active control stick assembly according toclaim 9 further comprising a second spring element compressed between the second radial flange and the housing assembly.

11. An active control stick assembly according toclaim 10 further comprising:

a first artificial force feel (AFF) actuator hingedly to the first radial flange, the first spring element disposed between the first AFF actuator and the spherical control stick support body; and

a second AFF actuator hingedly coupled to the second radial flange, the second spring element disposed between the second AFF actuator and the spherical control stick support body.

12. An active control stick assembly according toclaim 11 wherein the first AFF actuator and the second AFF actuator are disposed proximate the first spring element and the second spring element, respectively.

13. An active control stick assembly according toclaim 8 further comprising a rotary actuator mechanically linked to opposing end portions of the spherical control stick support body and configured to provide active force feedback to the control stick indicative of at least one flight parameter of the aircraft.

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